U.S. patent application number 17/518490 was filed with the patent office on 2022-05-05 for monolithic drain, tooling, and method of manufacturing the same.
The applicant listed for this patent is John Henry, Joshua Bernard Hitchcock, Brent Sherman. Invention is credited to John Henry, Joshua Bernard Hitchcock, Brent Sherman.
Application Number | 20220136227 17/518490 |
Document ID | / |
Family ID | 1000005999375 |
Filed Date | 2022-05-05 |
United States Patent
Application |
20220136227 |
Kind Code |
A1 |
Hitchcock; Joshua Bernard ;
et al. |
May 5, 2022 |
MONOLITHIC DRAIN, TOOLING, AND METHOD OF MANUFACTURING THE SAME
Abstract
A monolithic drain body including a base wall defining an outlet
and a periphery, a side wall extending from the periphery of the
base wall to produce an open end opposite the base wall, and a
ledge formed into the side wall and extending inwardly therefrom to
at least partially enclose a first volume between the ledge, the
side wall, and the base wall.
Inventors: |
Hitchcock; Joshua Bernard;
(Greenville, TX) ; Henry; John; (Rockwall, TX)
; Sherman; Brent; (Celeste, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hitchcock; Joshua Bernard
Henry; John
Sherman; Brent |
Greenville
Rockwall
Celeste |
TX
TX
TX |
US
US
US |
|
|
Family ID: |
1000005999375 |
Appl. No.: |
17/518490 |
Filed: |
November 3, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
63109334 |
Nov 3, 2020 |
|
|
|
Current U.S.
Class: |
138/177 |
Current CPC
Class: |
E03F 5/0407 20130101;
B21D 22/16 20130101 |
International
Class: |
E03F 5/04 20060101
E03F005/04; B21D 22/16 20060101 B21D022/16 |
Claims
1. A drain comprising: a base wall defining an outlet and a
periphery; a side wall extending from the periphery of the base
wall to define an open end opposite the base wall; and a ledge
formed into the side wall and extending inwardly therefrom to at
least partially enclose a first volume between the ledge, the side
wall, and the base wall, wherein the ledge forms a neck having a
first cross-sectional shape, wherein the first volume includes a
second cross-sectional shape that is larger than the first
cross-sectional shape, and wherein the base wall, side wall, and
ledge are formed from a monolithic material.
2. The drain of claim 1, wherein the monolithic material is a piece
of sheet material.
3. The drain of claim 1, wherein the monolithic material is formed
using a metal spinning technique.
4. The drain of claim 1, wherein the drain further comprises a
drain pipe coupled to the outlet and in fluid communication with
the first volume, wherein the drain pipe is formed from a second
piece of material different than the monolithic material.
5. The drain of claim 1, wherein the drain further includes a top
plate coupled to the open end of the side wall, wherein the top
plate is formed from a second piece of material different than the
monolithic material.
6. The drain of claim 1, wherein the drain defines a drain axis,
and wherein at least a portion of the base wall is oblique to the
drain axis.
7. The drain of claim 1, wherein the drain defines a drain axis,
wherein the base wall has a circular periphery, and wherein the
side wall extends axially from the periphery of the base wall.
8. The drain of claim 1, wherein the ledge extends inwardly from
the side wall along the entire circumference of the side wall.
9. The drain of claim 1, wherein the first cross-sectional shape is
a circle having a first diameter, and wherein the second
cross-sectional shape is a circle having a second diameter greater
than the first diameter.
10. A method of manufacturing a drain having a monolithic body, the
method comprising: providing a die with a first exterior surface;
forming a first monolithic piece of sheet material over the first
exterior surface of the die to produce the monolithic body, wherein
the monolithic body has an internal volume having a first
cross-sectional shape accessed via an aperture having a second
cross-sectional shape that is smaller than the first
cross-sectional shape; and removing the die from the internal
volume via the aperture.
11. The method of claim 10, wherein the die includes a head unit
and at least one die segment removably attached to the head unit,
and wherein the head unit and at least one die segment together
form the first exterior surface.
12. The method of claim 11, wherein removing the die from the
internal volume includes removing the head unit from the internal
volume via the aperture and subsequently removing the at least one
die segment from the internal volume via the aperture.
13. The method of claim 11, wherein the die segment is one of a
plurality of die segments, and wherein the plurality of die
segments together form the first cross-sectional shape.
14. The method of claim 10, further comprising forming the first
monolithic piece of sheet material over the first exterior surface
using a metal spinning process.
15. The method of claim 10, wherein the first cross-sectional shape
includes a circle having a first diameter, and wherein the second
cross-sectional shape includes a circle having a second diameter
smaller than the first diameter.
16. The method of claim 10, further comprising coupling a top plate
formed from a second piece of material to the monolithic body.
17. The method of claim 10, further comprising coupling a drain
pipe formed from a second piece of material to the monolithic
body.
18. A die having an external surface configured to at least
partially form an internal volume, the die comprising: a head unit
defining a die axis, wherein the head unit includes a first end and
a second end opposite the first end; a first die segment removably
coupled to the head unit, wherein the first die at least partially
forms the external surface; and wherein when the first die segment
is coupled to the head unit the resulting assembly produces an
assembled cross-sectional shape taken normal to the die axis and
passing through the first die segment, and wherein the first die
segment can be completely detached from the head unit without
extending outside the assembled cross-sectional shape during the
detachment process.
19. The die of claim 18, wherein the head unit defines a first
aperture that is open axially toward the second end, and wherein
the first die segment includes a first protrusion configured to be
at least partially received within the first aperture.
20. The die of claim 18, wherein the first die segment is one of a
plurality of die segments, and wherein when each of the plurality
of die segments are attached to the head unit the plurality of die
segments completely extend along and enclose the assembled
cross-sectional shape.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application is a non-provisional of and claims
priority to U.S. Provisional Patent Application No. 63/109,334,
filed Nov. 3, 2020, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present disclosure relates to a drain, and more
specifically to a drain formed from a single piece of material.
BACKGROUND
[0003] Internal volumes where the open end is smaller than the
diameter of the volume itself are typically formed by preparing two
or more separate pieces and welding the piece together to enclose
the volume therein. Such manufacturing techniques result in welded
seams that leave pockets in crevices therein which can become
contaminated by dirt, bacteria and the like.
SUMMARY
[0004] In one aspect, a drain including a base wall defining an
outlet and a periphery, a side wall extending from the periphery of
the base wall to produce an open end opposite the base wall, and a
ledge formed into the side wall and extending inwardly therefrom to
at least partially enclose a first volume between the ledge, the
side wall, and the base wall. Where the ledge forms a neck having a
first cross-sectional shape, where the first volume includes a
second cross-sectional shape that is larger than the first
cross-sectional shape, and where the base wall, side wall, and
ledge are formed from a single piece of monolithic material.
[0005] In another aspect, a method of manufacturing a drain having
a monolithic body, the method including providing a die with a
first exterior surface, forming a first monolithic piece of sheet
material over the first exterior surface of the die to produce the
monolithic body, where the monolithic body has an internal volume
having a first cross-sectional shape accessed via an aperture
having a second cross-sectional shape that is smaller than the
first cross-sectional shape, and removing the die from the internal
volume via the aperture.
[0006] In another aspect, a die having an external surface
configured to at least partially form an internal volume, the die
including a head unit defining a die axis, where the head unit
includes a first end and a second end opposite the first end, a
first die segment removably coupled to the head unit, where the
first die at least partially forms the external surface, and where
when the first die segment is coupled to the head unit the
resulting assembly produces an assembled cross-sectional shape
taken normal to the die axis and passing through the first die
segment, and wherein the first die segment can be completely
detached from the head unit without extending outside the assembled
cross-sectional shape during the detachment process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a side view of a prior art drain.
[0008] FIG. 2 is a top view of the prior art drain of FIG. 1.
[0009] FIG. 3 is a detailed side view of the prior art drain of
FIG. 1.
[0010] FIG. 4 is a side view of a drain having improved hygienic
properties.
[0011] FIG. 5 is a top view of the drain of FIG. 4.
[0012] FIG. 6 is a detailed side view of the drain of FIG. 4.
[0013] FIG. 7 is a side view of a body of the drain of FIG. 4.
[0014] FIG. 8 is a top view of the body of FIG. 7.
[0015] FIG. 9 illustrates multiple monolithic drain bodies.
[0016] FIG. 10 illustrates the drain of FIG. 4 with a circular top
plate installed thereon.
[0017] FIG. 11 illustrates a die in a disassembled state.
[0018] FIG. 12 illustrates the die of FIG. 11 with two die segments
installed on a head unit thereof.
[0019] FIG. 13 illustrates the die of FIG. 11 with three die
segments installed on the head unit thereof.
[0020] FIG. 14 illustrates the die of FIG. 11 with five die
segments installed on the head unit thereof.
[0021] FIG. 15 illustrates the die of FIG. 11 with all six die
segments installed on the head unit thereof.
[0022] FIG. 16 illustrates the die of FIG. 11 with the end segment
installed on the head unit thereof.
[0023] FIG. 17 is a bottom view of the die of FIG. 11.
[0024] FIG. 18 is a section view of FIG. 16 taken along line
18-18.
[0025] FIG. 19 is the section view of FIG. 18 with a monolithic
drain body formed thereon.
[0026] FIG. 20 is a bottom view of an alternative embodiment of the
die including a die segment having parallel side walls.
[0027] FIG. 21 is a section view taken along the centerline of a
structure having an internal volume.
[0028] FIG. 22 illustrates another embodiment of the drain having a
sloped base wall.
DETAILED DESCRIPTION
[0029] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting.
[0030] FIGS. 1-3 illustrate a prior art embodiment of a drain 5000.
The drain 5000 includes a multi-piece body 5002 defining an open
end 5016 and an outlet 5008, a top plate 5006 coupled (e.g.,
welded) to the multi-piece body 5002 at the open end 5016, and a
drain pipe 5010 coupled (e.g., welded) to the multi-piece body 5002
at the outlet 5008.
[0031] The multi-piece body 5002 includes a base wall 5004 defining
the outlet 5008, and a side wall 5012 extending axially from the
base wall 5004 to produce an open end 5016 opposite the base wall
5004. The drain 5000 also includes a ledge 5020 formed into and
extending radially inwardly from the side wall 5012 and positioned
proximate the open end 5016. The ledge 5020 extends along the
entire circumference of the side wall 5012 to "neck down" the open
end 5016 (see FIG. 2).
[0032] As shown in FIG. 1, the body 5002 is formed from multiple
pieces of sheet material welded together. More specifically, the
body 5002 includes a first piece of sheet material 5024 forming the
base wall 5004 and a portion of the side wall 5012 (e.g., forming a
shallow dish shape), and a second piece of sheet material 5028
welded to the first piece of sheet material 5024 forming the side
wall 5012 and the ledge 5020. In the illustrated embodiment, the
second piece of sheet material 5028 of the drain 5000 is formed as
an elongated flat piece that is formed into an annular shape by
welding the two distal ends together (e.g., forming an axial weld
5030 along the height of the side wall 5012). The resulting annular
shape is then welded to the first piece of sheet material 5024
producing a circumferential weld 5032 around the entire body 5002.
The resulting multi-piece welded drain structure has hygienic
deficiencies as both welded seams 5030, 5032 provide pockets and
crevices for contamination such as dirt, bacteria, gunk, and the
like to become lodged and fester. Such pockets and crevices are
also difficult, and in some cases impossible, to clean properly
[0033] FIGS. 4-10 illustrate the monolithic drain 10 having
improved hygienic properties. The drain 10 has a monolithic body 12
defining an open end 30 and an outlet 18, a top plate 16 coupled to
the open end 30 of the monolithic body 12, and a drain pipe 20
coupled to the outlet 18 of the monolithic body 12.
[0034] The top plate 16 of the drain 10 is a substantially planar
element formed from a first piece of material separate from the
monolithic body 12. The top plate 16 at least partially defines an
internal aperture 28 sized to substantially correspond with the
size and shape of the open end 30 of the monolithic body 12. As
shown in FIG. 5, the exterior shape of the plate 16 may be square,
however in alternative embodiments, the exterior shape of the plate
16 may be rectangular, circular, elliptical, polygonal, or any
other shape as needed (see FIG. 10). When assembled, the top plate
16 is fused (e.g., welded, soldered, brazed, and the like) to the
open end 30 of the body 12 such that the internal aperture 28
substantially aligns with and is open to the open end 30 of the
body 12. In alternative embodiments, the top plate 16 may be
mechanically fastened to the body 12 by brackets, fasteners,
press-fit, and the like (not shown).
[0035] The drain pipe 20 of the drain 10 is a substantially
cylindrical element at least partially defining a channel 36
therethrough. The drain pipe 20 is formed from a second piece of
material separate from the monolithic body 12. When assembled, the
drain pipe 20 is fused (e.g., welded, soldered, brazed, and the
like) to the base wall 14 (described below) of the body 12 so that
the channel 36 is substantially aligned with the outlet aperture 18
and open to the interior volume 40. In alternative embodiments, the
drain pipe 20 may be mechanically fastened to the body 12 by
brackets, fasteners, gaskets, press-fit, and the like (not
shown).
[0036] As shown in FIGS. 4-10, the monolithic body 12 of the drain
10 defines a body axis 16. The body 12 also includes a base wall 14
defining the outlet 18 and having an outer periphery, and a side
wall 26 extending from the outer periphery of the base wall 14 to
produce an open end 30 opposite the base wall 14 (see FIG. 5). The
size and shape of the side wall 26 also produces a first
cross-sectional shape having a first representative dimension 32
(see FIG. 5). For the purposes of this application, the
representative dimension of a cross-sectional shape may include any
dimension that generally establishes the size of the
cross-sectional shape. For example, a diameter may be a
representative dimension for a circle, a diagonal may be a
representative dimension for a square or rectangle, a diagonal may
be a representative dimension for a polygon, and the like.
[0037] In the illustrated embodiment, the base wall 14 has a
circular outer periphery and the side wall 26 extends axially
therefrom to produce a substantially cylindrical shape whereby the
first cross-sectional shape, taken normal to the axis 16, is
circular and the first representative dimension 32 is a first
diameter. However, in alternative embodiments, the periphery of the
base wall 14 and the side wall 26 may have alternative
cross-sectional shapes such as, but not limited to, square,
rectangular, polygonal, and the like. In instances where
alternative cross-sectional shapes are present, the side wall 26
may include a plurality of interconnected wall segments or portions
(not shown) to produce the desired cross-sectional shape (e.g.,
four wall segments to produce a square cross-sectional shape, and
the like).
[0038] The drain 10 also includes a ledge 34 formed into the side
wall 26 and extending inwardly therefrom between the base wall 14
and the open end 30 to produce an interior opening or neck 42. The
ledge 34 serves to at least partially enclose an interior volume 40
within the body 12 between the ledge 34, the side wall 26, and the
base wall 14 while the neck 42 defines an aperture through which
the volume 40 may be accessed.
[0039] As shown in FIG. 5, the neck 42 produces a second
cross-sectional shape that is smaller than the first
cross-sectional shape of the interior volume 40 and includes a
second representative dimension 38 that is less than the first
representative dimension 32 of the interior volume 40 (e.g., the
second cross-sectional area of the neck 42 is less than the first
cross-sectional area of the volume 40 enclosed by the ledge 34,
side wall 26, and base wall 14 when both cross-sections are taken
perpendicular to the axis 16). As such, the ledge 34 serves to
"neck down" the open end 30 of the body 12 and provide an upper
surface 44 upon which a strainer, basket, or other elements may be
supported when positioned within the drain 10. The ledge 34 is also
positioned proximate the open end 30 of the body 12. In the
illustrated embodiment, the neck 42 has a circular cross-sectional
shape (e.g., the second cross-sectional shape is a circle) having a
second representative dimension 38 that includes a second diameter
that is less than the first diameter of the side wall 26. However,
in alternative embodiments, different internal cross-sectional
shapes may be formed. In still other embodiments, the shape of the
first cross-sectional shape may be different than the second
cross-sectional shape.
[0040] Together, the ledge 34, side wall 26, and base wall 14 at
least partially enclose the interior drain volume 40 therein. In
the illustrated embodiment, the resulting drain volume 40 produces
at least one cross-sectional dimension that is larger than the
smallest cross-sectional dimension of the neck 42.
[0041] In the illustrated embodiment, the body 12 is monolithic,
such that it is formed from a single piece of continuous material
without joints or seams. More specifically, the illustrated body 12
itself does not include any welds or seams (e.g., between the base
wall 14, the side wall 26, and the ledge 34). The only seams
present in the drain 10 include the connection interfaces between
the body 12 and the drain pipe 20 and the body 12 and the top plate
16. By eliminating any joints or seams within the body 12 itself,
the body 12 of the drain 10 does not include any pockets or
crevices where bacteria and/or other contaminates may be captured
or trapped--producing a more hygienic structure overall.
[0042] FIGS. 11-19 illustrate a die 100 used to manufacture the
monolithic body 12 of the drain 10. Generally speaking, the die 100
is configured so that the die 100 can be positioned within and form
a structure 800 with an internal volume 804 having a first
cross-sectional shape producing a first representative dimension
808 that is accessible via an opening or aperture 816 having a
second cross-sectional shape that is smaller than the first
cross-sectional shape and producing a second representative
dimension 820 that is smaller than the first representative
dimension 808. More specifically, after the internal volume 804 of
the structure is formed by shaping the single piece of material
about the die 100, the die 100 is configured to be subsequently
removed from the resulting internal volume 804, in a first removal
direction 812, through the aperture 816 (see FIG. 21). Stated
differently, the die 100 is configured to produce an internal
volume 804 that is larger than the aperture 816 through which the
die 100 itself can be removed from the volume 804. As shown in FIG.
21, the relevant cross-sections are generally taken normal to the
direction of removal 812.
[0043] As shown in FIGS. 11-19, the die 100 includes a head unit or
base 104, and a plurality of die segments 108a, b each removably
coupled to the head unit 104. Together, the combined exterior
surfaces of the base 104 and die segments 108a, b define the size
and shape of the interior surfaces 60 of the monolithic body 12
(e.g., the surfaces 60 of the body 12 at least partially defining
the drain volume 40). Furthermore, the die 100 is configured so
that a sub-portion of the die 100 (e.g., the head unit 104) can be
individually removed from the drain volume 40 via the open end 30
whereby the remaining elements (e.g., the die segments 108a, b) can
be removed individually afterwards.
[0044] As shown in FIG. 18, the head unit 104 of the die 100
includes a substantially cylindrical body 110 defining an axis 114
therethrough. More specifically, the body 110 includes a first
portion 118 producing a first outer diameter 122, a second portion
126 extending axially from the first portion 118 to produce a
second outer diameter 130 less than the first outer diameter 122,
and a third portion 134 extending axially from the second portion
126 opposite the first portion 118 to produce a third outer
diameter 138 less than the second outer diameter 130, and a fourth
portion 140 extending axially from the third portion 134 to produce
a fourth outer diameter 144 that is less than the third outer
diameter 138 and a distal end 148.
[0045] The body 110 also defines a first groove or aperture 142 at
the interface of the first and second portions 118, 126, and a
second groove or aperture 146 at the interface of the second and
third portions 126, 134. As shown in FIG. 18, both the first groove
142 and the second groove 146 are open axially toward the distal
end 148 of the head unit 104. While the illustrated first and
second grooves 142, 146 are annular in shape and extend
continuously along the entire periphery of the head unit 104, it is
understood that in alternative embodiments the first groove 142
and/or second groove 146 may include a plurality of individual
apertures or segments spaced along the periphery of the head unit
104.
[0046] The head unit 104 also includes one or more torque pins 166
extending axially from the body 110 and configured to selectively
engage with a corresponding one of the die segments 108a, b and
transmit torque therebetween. More specifically, the torque pins
166 are configured to rotationally fix the die segments 108a, b
relative to the body 110. In the illustrated embodiment, the head
unit 104 includes a first torque pin 166 extending axially from the
second portion 126 of the body 110 and configured to selectively
engage with a corresponding radial segment 108a (discussed below),
and a second torque pin 166 extending axially from the fourth
portion 140 of the body 110 and configured to selectively engage
with and end segment 108b (discussed below).
[0047] As shown in FIG. 18, the die 100 also includes a plurality
of die segments 108a, b that are each removably couplable to the
head unit 104. More specifically, each die segment 108a, b is
attached to the head unit 104 such that it can be detached from the
head unit 104 without increasing the external dimensions of the die
100 perpendicular to the direction of removal 106. Stated
differently, the fully assembled die 100 (e.g., with all die
segments 108a, b attached to the head unit 104) produces an
assembled cross-sectional shape taken normal to the axis 16 and
passing through the die segments 108a. Each die segment 108a, b is
configured so that it can be completely detached from the head unit
104 without having any of the die segments 108a, b extend outside
the assembled cross-sectional shape. In the illustrated embodiment,
each die segment 108a, b is attached to the head unit 104 so that
each can be removed axially from the head unit 104. More
specifically, the die segments 108a, b are configured so that the
head unit 104 can simultaneously detach from all of the die
segments 108a,b in a direction of removal 106.
[0048] In the illustrated embodiment, the die 100 includes one or
more radial segments 108a and at least one end segment 108b.
Together, the exterior surfaces of the segments 108a, b at least
partially define the contour of the ledge 34, the side wall 26, and
the base wall 14 (see FIG. 0.19). More specifically, the segments
108a, b determine the size and shape of the base wall 14, the
bottom and interior surfaces 48, 52 of the ledge 34, and the
portion 56 of the side wall 26 located axially between the bottom
surface 48 of the ledge 34 and the base wall 14.
[0049] Each radial segment 108a of the die 100 includes an arcuate
body 150 with an arcuate outer surface 154. Each radial segment
108a also includes first protrusion 170 extending axially from a
first end of the arcuate body 150 and a locking member 158
extending from the inner surface 162 of arcuate body 150. As shown
in FIG. 18, the outer surface 154 of each radial segment 108a
contributes to the overall size and shape of the body 12 of the
drain 10 (see FIG. 19).
[0050] The first protrusion 170 of each radial segment 108a is
sized and shaped to be at least partially received within the first
groove 142 of the head unit 104. More specifically, the first
protrusion 170 is sized and shaped so that it can be axially
inserted into the first groove 142 whereby the interaction between
the groove 142 and the protrusion 170 will restrict any radial
movement between the segment 108a and the head unit 104.
[0051] The locking member 158 of the radial segment 108a is
substantially "L" shaped having a radial leg 174 and an axial leg
178. The legs 174, 178 are sized and shaped so that the axial leg
178 may be at least partially inserted into and removed from the
second groove 146. More specifically, the locking member 158 is
sized and shaped so that it can be axially inserted into the second
groove 148 whereby the interaction between the groove 148 and the
locking member 158 will restrict any radial movement between the
segment 108a and the head unit 104.
[0052] As shown in FIG. 15, the illustrated die 100 includes a
plurality of radial segments 108a that, together, form a toroidal
shape extending a complete 360 degrees around the head unit 104.
More specifically, the exterior surfaces 154 of the radial segments
108a interact with each other to form a substantially smooth
cylindrical shape. As shown in FIG. 15, the die 100 includes five
radial segments 108a where the angular width of each radial segment
108a is different. However, in alternative embodiments, more or
fewer segments 108a may be used with different or similar angular
widths as needed to complete the entire 360 degree structure. In
one alternative embodiment, at least one of the radial segments
108a' may include parallel side walls in place of a wedge shape so
that the piece can be more easily removed after the head unit 104
has been removed (see FIG. 20).
[0053] At least one of the radial segments 108a defines an aperture
182 formed into the locking member 158 and configured to at least
partially receive a portion of the first torque pin 166 therein.
More specifically, when axially attaching the radial segment 108a
to the head unit 104, the torque pin 166 is axially aligned with
and received within the aperture so that the corresponding radial
segment 108a and head unit 104 are rotationally fixed. In the
illustrated embodiment, the radial segment 108a with the smallest
angular width includes the aperture 182. Furthermore, while the
illustrated torque pins 166 are included in the head unit 104, in
alternative embodiments the segments 108a may include the pins 166
while the head unit 104 defines the aperture 182.
[0054] While the illustrated embodiment shows the plurality of five
radial segments 108a producing a substantially cylindrical outer
surface extending 360 degrees about the head unit 104 (e.g., the
assembled cross-sectional shape is a circle), it is understood that
in alternative embodiments the plurality of radial segments 108a
may be coupled to a head unit 104 to produce other exterior shapes
such as square, rectangular, polygonal, elliptical, and the like.
In such embodiments, the radial segments 108a may still extend
along and enclose the entire assembled cross-sectional shape.
[0055] As shown in FIGS. 18, 19, and 16, the end segment 108b is
substantially disk shaped having a body with an exterior periphery
186 that substantially corresponds with and aligns with the radial
segments 108a of the die 100. During use, the end segment 108b
includes a first portion 190 that is configured to at least
partially form the base wall 14 of the body 12, and a second
portion 194 that is configured to at least partially form the
outlet 18 of the body 12. In some embodiments, the end segment 108b
may be interchangeable such that different sized and located
outlets 18 may be formed (not shown).
[0056] The end segment 108b also includes an aperture 200
configured to at least partially receive a portion of the second
torque pin 166 therein. As discussed above, the torque pin 166 is
configured to rotationally lock the end segment 108b to the head
unit 104 such that the two elements rotate together as a unit.
[0057] While the illustrated end segment 108b is disk-shaped, it is
understood that the exterior size and shape of the end segment 108b
may be changed to adapt to the correspond with and align to the
radial segments 108a of the die 100.
[0058] To manufacture the monolithic body 12 of the drain 10, the
user first assembles the die 100. To do so, each of the individual
radial segments 108a are coupled to the head unit 104 by axially
inserting the first protrusion 170 and locking members 258 into the
first and second grooves 142,146, respectively (see FIGS. 11-15).
The radial segments 108a are typically inserted from largest to
smallest but any order can suffice. While assembling the radial
segments 108a to the head unit 104, the user takes care to align at
least one of the radial segments 108a such that the corresponding
torque pin 166 is received within its corresponding aperture 182.
Since each of the assembled radial segments 108a are in contact
with each other to form the finished structure, only one of the
segments 108a need be secured with a torque pin 166 to allow the
entire assembly to remain rotational fixed relative to the head
unit 104.
[0059] With the radial segments 108a in place, the user may then
axially introduce the end segment 108b onto the distal end of the
head unit 104 (see FIG. 16). As discussed above, the end segment
108b encloses the distal end of the head unit 104 such that the
exterior surfaces of the radial and end segments 108a, 108b produce
a substantially continuous "cup" shape.
[0060] With the die 100 prepared, the user then forms a piece of
sheet material (e.g., a piece of stainless steel sheet material,
aluminum sheet material, steel sheet material, and the like) onto
the assembled exterior surface of the die 100 (e.g., the exterior
surface defined by the end segment 108b, the radial segments 108a,
and the exterior exposed portions of the head unit 104). In the
illustrated embodiment, this is done using a "metal spinning"
process whereby the raw material (e.g., a planar disk of sheet
material) and die 100 are spun together and the sheet material is
formed against the exterior surface of the die using tools so that
the sheet material takes on the contour of the exterior surface of
the die 100. Such forming produces the base wall 14, outlet 18,
side wall 26, and ledge 34. In alternative embodiments, other forms
of material shaping could be used. For example, in some embodiments
a separate external die may be paired with the illustrated die 100
for a pressing action. In still other embodiments other forms of
shaping may be used to form the sheet material against the exterior
surface of the die 100.
[0061] With the monolithic body 12 of the drain 10 formed, the user
then axially removes the head unit 104 from the volume 40. More
specifically, the head unit 104 is axially retracted from the
volume 40 via the open end 30 in the removal direction 106 whereby
the radial and end segments 108a, 108b remain within the formed
volume 40. More specifically, the process of removing the head unit
104 causes each of the radial and end segments 108a, 108b to
simultaneously detach from the head unit 104 allowing the head unit
104 to be removed from the neck 42 of the ledge 34.
[0062] With the head unit 104 removed, the radial segments 108a may
then be removed through the aperture or neck 42 one at a time.
Generally speaking, this is typically starting with the smallest
segment and then removing any increasingly larger segments 108a in
due course but any order may be used. With the radial segments 108
removed from the volume 40, the end segment 108b may then be
removed last leaving the finished body 12.
[0063] In some embodiments, the finished body 12 may then be
further assembled by welding or otherwise coupling the top plate 16
and drain pipe 20 to the body 12 in the appropriate locations.
[0064] FIG. 22 illustrates another embodiment of the drain 10'. The
drain 10' is substantially similar to the drain 10 so only the
differences will be discussed herein. More specifically, the body
12' of the drain 10' includes a base wall 14' that that is
substantially frusto-conical in shape such that the base wall 14'
is oblique to the axis 16' of the drain 10' to encourage better
drainage by directing any fluids contained within the volume 40'
into the drain pipe 20' attached to the outlet 18'.
[0065] Although the invention has been described in detail with
reference to certain preferred embodiments, variations and
modifications exist within the scope and spirit of one or more
independent aspects of the invention as described.
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